93' TSI Street Bruiser

[bjjnerd85]

Subscribed to this thread. Cant wait to see how it turns out. Good luck. Looks like you got it goin on tho. ;-)

 

[6772owner]

Thanks bjjnerd85,

Unfortunetly I attempted to install the engine lastnight and my tensioner setup is too wide, it wont allow the rear engine mount to line up before it hits the unibody... so I pulled the engine back out and Im going to delete the tensioner, get a shorter belt and just slot the upper mounting hole. Fingers crossed that I can get enough tension and still clear the subframe and p/s lines. I forgot to take pics of the disaster, but will update later this week when I try again.

 

[6772owner]

Update:

I purchased a shorter belt and slotted out my upper alternator mounting bracket, everything lined up and tightened up nicely. I double checked everythign and installed the engine successfully this time! I started routing the engine harness and working on mounting the distribution blocks for the battery feeds. I will get some pics up tonight, I didnt take any while working.

 

[6772owner]

Ok all, I finally took some pics of the engine in place and about half wired. I feel like I'm getting somewhere now... I also started to finalize the distribution blocks and mock up the power connections.

I also found out I had the incorrect flywheel bolts, so I ordered a set of OE bolts, along with some heat shrink, braided loom, relays and a pair of catch cans. I am going to have one between the PCV valve and I/M, as well as one between the valve cover breather and the air intake. This seems to be a good setup to start at least, I bought some cheap catch cans for now to try it out.

Pics:

 

[6772owner]

Update:

Lastnight I installed my new lift supports (PITA), finished the trim panels for the trunk floor, bolted them down, trimmed out the carpet for the battery box and put everything back together. Hopefully I am done with that area for awhile (minus installing a new battery). I also worked on wiring up relays for the fans and organizing all the front end parts for reinstallation.

The OEM flywheel bolts I ordered showed up, so I will hopefully get the trans installed this weekend so I can install the starter and finish up the wiring from there. Then I just need to wrap up the alternator wiring and the harness at the OFH.

I will post some pics tonight or tomorrow, I didnt take any lastnight.

Update:

Lastnight I installed my new lift supports (PITA), finish the trim panels for the trunk floor, bolted them down, trimmed out the carpet for the battery box and put everything back together. Hopefully I am done with that area for awhile (minus installing a new battery). I also worked on wiring up relays for the fans and organizing all the front end parts for reinstallation.

The OEM flywheel bolts I ordered showed up, so I will hopefully get teh trans installed this weekend so I can install the starter and finsih up the wiring there. Then I just need to wrap up the alternator wiring and the harness at the OFH.

I will post some pics tonight or tomorrow, I didnt take any lastnight.

 

[6772owner]

Pics:

Fan harness built, just need to hook up the power and ground connections for the relays.

 

[6772owner]

Small update today, I ordered more electrical connectors so I can build my ground cables, also ordered more heat shrink for the fan relay harness. I am hoping to be done with the wiring this weekend, then I need to install the oil cooler, all the ducting and the bumper cover next.

Also have a newbie question, what do you guys do for spark plug sockets on these things?

 

[6772owner]

Updates:

I figured out the spark plugs are 13/16", the socket I had was too thick to fit into the head, so I thought it was too large..

I installed the charge wire, starter power cable, finished up the alternator wiring and cleaned up the harness at the OFH. I need to finish making ground cables next and then I can move onto the I/C piping, air intake, etc.

Pics:

 

[6772owner]

I installed the GM MAF, routed the ECM Link harness and started on the I/C piping.

MBC mounted, hopefully this location doesnt have too much heat.

 

[1slowhatch]

Making great progress!

 

[6772owner]

Thanks, Im trying, just havent had as much time as Id like to work on it. Hoping to get it running by April, Im getting antsy now...

 

[curt-s]

Be patient and don't rush -- that's when mistakes/shortcuts are taken and you end up leaving rod caps on the highway.

 

[6772owner]

No doubt, I agree, luckily I have a checklist to keep me in focus. Im not necessarily "rushing" anything, Id just like to be driving this thing now after all this work is all.

 

[6772owner]

I finally picked up a battery last weekend, I ended up just getting the factory replacement for my DD (12' Malibu) in case I would need to switch the batteries for some reason... I figured it should have enough power, it is sealed, 3 year full replacement warranty and has the built in vent tube port also. I used some peel-n-seal on the bottom of the battery box to help cushion the battery and keep the rattles down hopefully.

I then finished the wiring on the OFH, mounted the I/C duct, fog lamp duct and then starting working on my oil cooler. I was thrilled to find out I can use the existing bolt hole from the p/s cooler on one end and then I will fab a bracket for the drivers side. I think I am just going to bend up an aluminum plate and bolt it to the side of the rad support, I will post pics when I get to that.

I finalized the I/C piping and air intake as well, here are a few pics, let me what you think... It gets tight over there with all three pipes in one area, I cant wait to switch to a bigger turbo and FMIC to reduce some of the clutter in one area. Also threw in some plugs, shortened the COP harness a bit and soldered/heat shrunk all the wiring.

Pics:

Cleaned up the drivers side a bit to get some of the dust layers off.

 

[6772owner]

Well, I didnt get as far as I wanted too, but mounted up the oil cooler and started working on the radiator duct. Once I have the duct trimmed to clear the oil cooler I can put the bumper cover on hopefully.

Pics:

SMIC Duct:

 

[6772owner]

Sorry for the lack of updates, I've been slammed with a ton of stuff. Anyway, I finally installed the oil cooler, all ducts, the bumper cover and headlights. I had to order new park lenses also, found out one of mine had broken mounting points.

Pics:

 

[6772owner]

Ok all, I need some help/advise: I hooked up my Link cable and laptop yesterday to to see if I could start working with Link. I had no light (power) on the Link cable and it wont communicate (obviously), any ideas on why I dont have power at the DTC port? I checked my fuse at under the hood (which is in my distribution block now) and used my Power Probe to verify voltage. I also noticed that my fuel pump wasnt turning on, I did remove the fuel pressure solenoid, does that have to stay plugged in for the fuel system to operate? I havent tried to crank/start yet due to not being that far yet. The PCM was socketed and installed straight out of the box from ECM Tuning.

Note: I did do some searching and came across a few things to check, but most of what I found was for 2G or just said it was a bad ECU?

 

[bjjnerd85]

Did you download the drivers with the program? All my connection problems have came from the drivers. If so uninstall and re install both.

 

[92AWDHX40]

MMM thats i found my fuse blew and didnt have power to it, try downloading the updates again.

 

[6772owner]

Thanks guys, I will try that, I just feel that the LED on the Link cable should be lite up when I have the key on and trying to connect correct?

iugrad92turbo, which fuse was that on a 1G? I didnt see any blown, but I also wasnt sure what I looking for. The cig lighter does work, I have always associated those two from my domestic car days.

 

[Rsawd95dsm]

Know anyone else that has link? Could try swapping link cords. On my 1G link stopped communicating with my laptop and I had to get a new cord and it works again.

 

[6772owner]

Thanks, I can try that as well, this cord is brand new/never used. It still had the twist ties on it when I took it out of the box... Doesnt mean its not a "bad" cable though, thanks for the suggestion.

 

[Rsawd95dsm]

When you have link on the laptop and the cord plugged in does the little black box on the cord, blink the green light at all?

 

[6772owner]

Not that I noticed, I will hook it up again and try, but I dont think I was getting any light at all. I also did not have 12V at the pin with the key on, so Im assuming that I have an electrical/fuse issue somewhere. I also havent checked it out, but my fuel pump doesnt seem to be running with the key on either, could be related or a separate issue I suppose.

 

[6772owner]

Ok all, I havent had a chance to plug my lap top back into the car yet, I will get to that this weekend. I did wrap up a few small things while I had a few minutes though. I ordered new clear park lamps and LED bulbs to go with them, the ones that came with car had broken mounting tabs and I didnt feel like fixing them. I also cleaned up some wiring under the hood and made a new return line.

Next up is finishing up the exhaust, I need to make one hanger and tighten everything up, vac lines for the emissions equipment, add fluids and get Link up and running.

Here are a few quick pics, I also washed the front wheels/tires up while they were off for CV installation.